thanks fellas.
For prosperity:
MK1 heater core:270x80x100
mk2 heater core:260x50x160
 
The washup for me, was after all that, the core's actually pretty fine. Any water I had floating around at the start of refitting just came from that on the myriad of fins. I refilled it, tested it with a set of manky 53yo lungs, and it didnt leak.
I like the bypass valve idea, and prob do that also.
So the heaters back together, I've found the dash vents and controls so will stick it in next.
May as well start the dash and firewall wiring whilst the tennis is on at night.

Since the heater was in, the gauges and crashpad were test fitted next.
Unfortunately the collection of bits that came with the van, didnt include a few things, like a wiper motor, and the trim that goes around the heater vent controls amongst others. I think wiper arms might be there though.

The crashpad that came with it is a fibreglass repro, that has been vinyl covered.
 
I knew it needed some love, but it actual fit was pretty poor around the gauge cluster.
The pic mightn't show it, but i'm petty sure you can see Perth through the gap, so might need to be on the lookout for a replacement. 
That or some foam seal.

 
everything has to come back out, to fit the loom, and wiper motor when I find one, but it was good to see the interior for the first time.
Poverty pack van cluster is growing on me.
The weird logo/crest thing  in the centre is pretty weird though. Not sure what Forrd designers were aiming for back then.
 
 
 

Also, the crashpad in the van left lots of the steel underdash visible, more than I expected.
Does the windscreen leading edge portion normally get body colour painted, or done in satin black?
And  the front of the dash itself? The 4 door has the 'ghia' plastic trim.
 
I'll check the Marty load lugger thread for inspiration as well.
 

Yep the dash between the windscreen and pad is finished in satin black. This is mine.


 
You can see where the dust from it sitting so long gathered 

Cause I am always painting a bare shell I always paint the dash section the same as the outside colour. Never really thought about black etc. I am pretty sure the section you refer to was a matt black in production line cars

#2 for Satan Black , or do it any colour you choose. Did a mates in metallic Black with a flat gloss clear coat. The load lugger was done in gloss, it's all I had and it matched the diff, tank, springs etc

whoa, how to confuse a bloke.
I think its the heat.
My first impresion of PTMs dash pic what its was white with a dust layer., must be time for a checkup with the optomo.
I saw an SA red van painted with the dash in body colour, which looked ok.
Trying to get my head around metallic black with flat gloss clear coat, in Satan black, but is sound like the ducks proverbials.
Thanks all for the pics, lets do Satan black, on the windscreen front edge, and body grey on the main facing.

Your heat is nothing to ours, Should've been here yesterday, 42 deggos in the shade and in the work shed it was about 55, to hot to sweat.
There is no flat gloss clear just flat clear additive for gloss. Great for ghost stripes..
To confuse you more on choice, way back in the 90s I did my mk2 day panel in XD Falcon charcoal just so it matches the grey carpet n chairs..
I'd like to see your satin black and grey facing panel, different approach, it will make the crash pad look more bigger in a way 👍.

Found out my mk1 Escort didn't have a heater box so I'll be adapting a metal case mk2 box which means the switch cluster will be used as well, argh it !

Also, incase you want one, there might be some face plates for the heater controls popping up on FB via one of the clubs.
Apparently there are different ones for early/late metal/plastic versions of the controls.
 
Matt stripes over gloss: everywhere now, but you where ahead of your time!
 
 

The heater box I have laying about in the barn has the cables and switch panel so it's all there to play with.
When doing the the load lugger I bought 2x stickers for the control switch plate from UK, can't find the other one so might just order it again...

Ghost stripes without being stripey!!